A laser cutting machine cyclic processing control system and method

Abstract

This invention belongs to the field of laser cutting, specifically relating to a laser cutting machine cyclic processing control system and method. It includes a safety relay, an emergency stop input module and a ready input module connected to the safety relay, and related relays. The emergency stop input module controls the conduction of the dual safety circuit of the safety relay, and the ready input module controls the conduction of the reset circuit of the safety relay. Based on the working principle of the safety relay's dual safety circuit conduction followed by reset, a hard enable signal is sent to the processing console. The processing console responds to the hard enable signal to perform worktable exchange or cyclic processing. During processing, the operator performs loading / unloading operations and safety relay control operations from behind the equipment, eliminating the need to go to the front of the equipment. This achieves safe operation and cyclic processing, reducing operator complexity and improving work efficiency while ensuring safe loading / unloading.

Description

Technical Field

[0001] This invention belongs to the field of laser cutting, specifically relating to a laser cutting machine cyclic processing control system and method. Background Technology

[0002] In the field of laser cutting, with the rapid development of the manufacturing industry, the requirements for processing efficiency and ease of operation are increasing. To improve production efficiency, laser cutting equipment is often equipped with dual exchange platforms. However, the current operating methods of this type of equipment have many shortcomings, especially in terms of the portability of the operating process. Particularly in batch production processes requiring manual loading and unloading, the complex operating procedures lead to low processing efficiency.

[0003] The existing laser cutting machine has its control panel at the front and the cutting table at the rear, requiring loading and unloading to be done from the back of the machine. To facilitate this exchange, an external button has been installed at the rear to control the table exchange. However, this still requires workers to go to the front control panel or use a handle to start processing each time. This operating method is inefficient for batch processing of identical tools, cumbersome for workers, and reduces processing efficiency for the factory.

[0004] Related technologies disclose a control method for a laser cutting workstation with loading and unloading capabilities. The method involves a robotic arm for loading and unloading. When a loading completion signal is detected from the workstation, a loading completion event is triggered. During the loading completion event processing, a laser cutting machine table exchange is initiated. When a table exchange completion signal is detected, a table exchange completion event is triggered. During the table exchange completion event processing, the calibration, edge finding, and cutting of the first sheet material are initiated, while simultaneously the robotic arm loads the second sheet material onto the second workstation. However, this method, applied to robotic arm loading and unloading scenarios, relies on feedback signals for table exchange and automatic cutting, and does not solve the problem of complex operation procedures in manual loading and unloading scenarios. Summary of the Invention

[0005] To address the aforementioned problems, this invention provides a laser cutting machine cyclic processing control system and method, which reduces the operational complexity for operators and improves work efficiency while ensuring the safety of loading and unloading materials.

[0006] In a first aspect, the technical solution of the present invention is a laser cutting machine cycle processing control system, including a safety relay, a relay KA1, a relay KA2, an emergency stop input module, a ready input module, and a proximity sensor for detecting the position of the worktable.

[0007] The coil of relay KA1 is connected to the positive terminal of the power supply at its first end and to the negative terminal of the power supply at its second end via a proximity sensor. The first normally open contact of relay KA1 is connected to the first input terminal one of the safety relay via an emergency stop input module, and the second contact is connected to the first input terminal two of the safety relay. The second normally open contact of relay KA1 is connected to the second input terminal one of the safety relay via an emergency stop input module, and the second contact is connected to the second input terminal two of the safety relay. The proximity sensor is connected to the machining control console.

[0008] The coil of relay KA2 is connected to the first output terminal of the first channel of the safety relay and the second output terminal of the first channel of the safety relay to the negative terminal of the power supply. The first output terminal of the safety relay is connected to the positive terminal of the power supply. The normally closed contact of relay KA2 is connected to the first reset branch terminal of the safety relay via the ready input module and the second contact of the safety relay to the second reset branch terminal of the safety relay. The normally open contact of relay KA2 is connected to the machining control console to transmit the hard enable signal to the machining control console and the second contact of the relay is connected to the negative terminal of the power supply.

[0009] The emergency stop input module and the ready input module are controlled manually or in combination with automatic operation at the rear of the equipment to activate the safety relay. In turn, the relay KA2 is activated, which transmits the hard enable signal to the processing control console. The processing control console responds to the hard enable signal to perform worktable exchange or cutting processing.

[0010] In one optional implementation, the emergency stop input module is an emergency stop button SB1, and the ready input module is a ready button SB2. The emergency stop button SB1 and the ready button SB2 are located at the rear of the device.

[0011] In an optional implementation, the emergency stop input module includes resistors R1, R2, and R3, capacitor C1, N-channel MOSFET Q1, diode D1, relay KA4, and switch ST; switch ST is located at the rear of the device.

[0012] The first end of resistor R1 is connected to the first output terminal of the processing console, and the second end is connected to the gate of MOSFET Q1 in one path and to the negative terminal of the power supply through resistor R2 in another path. Capacitor C1 is connected in parallel with resistor R2. The drain of MOSFET Q1 is connected to the positive terminal of diode D1, and the negative terminal of diode D1 is connected to the power supply. The source of MOSFET Q1 is connected to the negative terminal of the power supply.

[0013] The coil of relay KA4 is connected in parallel with diode D1. One end of the first normally closed contact of relay KA4 is connected to the first input terminal of the safety relay, and the other end is connected to the first terminal of the first normally open contact of relay KA1. One end of the second normally closed contact of relay KA4 is connected to the second input terminal of the safety relay, and the other end is connected to the second terminal of the second normally open contact of relay KA1.

[0014] One end of switch ST is connected to the input terminal of the machining control console, and the other end is connected to the pull-up power supply via resistor R3. The second end of switch ST is connected to the negative terminal of the power supply.

[0015] In an optional implementation, the ready input module includes resistor R4, resistor R5, capacitor C2, N-channel MOSFET Q2, diode D2, relay KA5, and timer;

[0016] The first end of resistor R4 is connected to the second output terminal of the processing console, and the second end is connected to the gate of MOSFET Q2 in one path and to the negative terminal of the power supply through resistor R5 in another path. Capacitor C2 is connected in parallel with resistor R5. The drain of MOSFET Q2 is connected to the positive terminal of diode D2, and the negative terminal of diode D1 is connected to the power supply. The source of MOSFET Q2 is connected to the negative terminal of the power supply.

[0017] The coil of relay KA5 is connected in parallel with diode D2. The first terminal of the normally open contact of relay KA5 is connected to the reset branch terminal of the safety relay, and the second terminal is connected to the normally closed contact of relay KA2.

[0018] The timer is connected to the machining control console.

[0019] In an optional implementation, the system also includes a camera connected to a processing console via a gateway. The processing console analyzes the worktable images captured by the camera to determine whether loading and unloading have been completed.

[0020] In an optional implementation, the system also includes a relay KA3 and an indicator LED;

[0021] The first end of the coil of relay KA3 is connected to the first output terminal of the second safety relay, and the second end is connected to the negative terminal of the power supply. The second output terminal of the safety relay is connected to the positive terminal of the power supply. The first end of the normally open contact of relay KA3 is connected to the positive terminal of the power supply, and the second end is connected to the negative terminal of the power supply via the indicator LED. The normally closed contact of relay KA3 is connected in series with the normally closed contact of relay KA2.

[0022] Secondly, the technical solution of the present invention provides a laser cutting machine cyclic processing control method, implemented based on any of the above-mentioned systems, comprising the following steps:

[0023] Import the image files that need to be processed in batches into the processing console;

[0024] Set the number of processing cycles on the display screen of the machining console, click "Start Machining", and configure the state machine of the machining console to the "Ready to Machining" state.

[0025] The proximity sensor detects whether the workbench is in position. If it is in position, the safety relay is activated by manual operation or manual-automatic operation at the rear of the equipment through the emergency stop input module and the ready input module.

[0026] When the processing controller receives the hard enable signal, it executes the cutting process and configures the state machine to the processing in progress state.

[0027] Once the current processing is completed, the safety relay is disconnected automatically or manually via the emergency stop input module from behind the equipment.

[0028] The processing controller configures the state machine to the processing completed state and checks whether the processing count has been reached.

[0029] If this condition is met, the state machine will be configured to indicate that processing is complete.

[0030] If the desired state is not achieved, the safety relay will be disconnected automatically or manually via the emergency stop input module from the rear of the equipment, and the state machine of the processing console will be configured to be ready to exchange worktables.

[0031] After loading and unloading are completed, the safety relay is activated at the rear of the equipment by manual operation or manual-automatic operation through the emergency stop input module and the ready input module.

[0032] When the machining controller receives the hard enable signal, it executes a table exchange and configures the state machine to be in the table exchange state.

[0033] The proximity sensor detects whether the worktable is in position. If it is in position, the cutting process is executed, and the processing status is configured in the state machine. This cycle is repeated until the processing is completed.

[0034] In an optional implementation, the safety relay is manually activated via an emergency stop input module and a ready input module at the rear of the device, specifically including:

[0035] Release the emergency stop button SB1, and then press the ready button SB2 to activate the safety relay;

[0036] The safety relay is manually disconnected via an emergency stop input module located at the rear of the equipment. Specifically, this includes:

[0037] Press the emergency stop button SB1 to disconnect the safety relay.

[0038] In an optional implementation, the safety relay is controlled by a manual operator in conjunction with an automatic system via an emergency stop input module and a ready input module at the rear of the device. Specifically, this includes:

[0039] Press the switch ST;

[0040] The machining control console detects whether it has received a signal from switch ST.

[0041] When the ST-scan signal is received, a low level is output at the first output terminal to turn off the emergency stop input module, and the first normally closed contact and the second normally closed contact of relay KA4 remain closed.

[0042] Receive images of the workbench area and analyze them to determine whether loading and unloading are complete.

[0043] If the loading and unloading are completed by analyzing the image of the workbench area, a high level is output at the second output terminal to turn on the ready input module, and the normally open contact of relay KA5 closes to turn on the safety relay.

[0044] When the second output terminal outputs a high level, a timer is used to count the time. After a preset time, the second output terminal outputs a low level, which turns off the ready input module and opens the normally open contact of relay KA5.

[0045] The safety relay is automatically disconnected via the emergency stop input module, specifically including:

[0046] A high level is output at the first output terminal to turn on the emergency stop input module, and the first normally closed contact and the second normally closed contact of relay KA4 are opened to disconnect the safety relay.

[0047] In one optional implementation, analyzing the image of the workbench area to determine whether loading and unloading are complete specifically includes:

[0048] Perform grayscale processing on the workbench area image;

[0049] Based on the predefined positions of the first and second worktables, the worktable area image is segmented into a first region and a second region;

[0050] Illumination compensation is performed on the first and second regions respectively using a Gaussian filter kernel;

[0051] The first and second regions are subjected to Gaussian filtering using the following formulas for noise reduction.

[0052]

[0053]

[0054]

[0055] in, , Indicates the Gaussian filtering result of the first... Coordinates in each region pixel values, The size of the Gaussian kernel is determined. Indicates the first Gaussian function of each region Indicates the first The standard deviation of the Gaussian distribution in each region Indicates the first The standard deviation of gray levels in each region;

[0056] The material coverage rates of the first and second regions are calculated using the following formulas, respectively.

[0057]

[0058]

[0059] in, Indicates the first Inter-frame difference binary map of each region;

[0060] Extract the number of valid contours in the first and second regions respectively;

[0061] The presence of materials in the first region is determined by the material coverage rate and the number of effective outlines in the first region; the presence of materials in the second region is determined by the material coverage rate and the number of effective outlines in the second region.

[0062] If there is no material in the first area and there is material in the second area, then the loading and unloading is considered complete.

[0063] The present invention provides a laser cutting machine cyclic processing control system and method, which, compared with the prior art, has the following advantages: It includes a safety relay, an emergency stop input module and a ready input module connected to the safety relay, and related relays. The emergency stop input module controls the conduction of the dual safety circuit of the safety relay, and the ready input module controls the conduction of the reset circuit of the safety relay. Based on the working principle of the safety relay being activated by resetting after the dual safety circuit is activated, a hard enable signal is sent to the processing console. The processing console responds to the hard enable signal to perform worktable exchange or cyclic processing. During processing, the operator performs loading / unloading operations and safety relay control operations from behind the equipment, eliminating the need to go to the front of the equipment. This achieves safe operation and cyclic processing, reducing the operator's operational complexity and improving work efficiency while ensuring safe loading / unloading. Attached Figure Description

[0064] To more clearly illustrate the technical solution of the present invention, the accompanying drawings used in the description will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0065] Figure 1 This is a schematic diagram of a laser cutting machine cyclic processing control system provided in an embodiment of the present invention.

[0066] Figure 2 This is a schematic diagram of a specific embodiment of a laser cutting machine cyclic processing control system provided by the present invention.

[0067] Figure 3 This is a schematic diagram of another specific embodiment of a laser cutting machine cyclic processing control system provided by the present invention.

[0068] Figure 4 This is a schematic diagram of a laser cutting machine cyclic processing control method provided in an embodiment of the present invention. Detailed Implementation

[0069] To make the objectives, features, and advantages of this invention more apparent and understandable, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings of the specific embodiments. Obviously, the embodiments described below are only some embodiments of this invention, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0070] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0071] Figure 1 This is a schematic diagram of a laser cutting machine cyclic processing control system provided in an embodiment of the present invention, as shown below. Figure 1 As shown, the system includes a safety relay, relay KA1, relay KA2, an emergency stop input module, a ready input module, and a proximity sensor. The proximity sensor detects whether the worktable is in position, meaning whether it is at the cutting / processing location.

[0072] The coil of relay KA1 has its first terminal connected to the positive terminal of the power supply, and its second terminal connected to the negative terminal of the power supply via a proximity sensor. The first normally open contact of relay KA1 has its first terminal connected to the first input terminal S11 of the safety relay via an emergency stop input module, and its second terminal connected to the second input terminal S12 of the safety relay. The second normally open contact of relay KA1 has its first terminal connected to the second input terminal S21 of the safety relay via an emergency stop input module, and its second terminal connected to the second input terminal S22 of the safety relay. The proximity sensor is connected to the machining control console. When the proximity sensor detects that the worktable (which can be any worktable) is in position, the proximity sensor closes, the coil of relay KA1 conducts, and the first and second normally open contacts close. In this state, when the emergency stop input module is activated, the dual circuit of the safety relay is activated, allowing the reset circuit of the safety relay to conduct. This activates the safety relay, providing a hard enable signal to the machining control console. In this state, when the emergency stop input module is deactivated, the dual circuit of the safety relay is deactivated, the safety relay cannot conduct, and the machining control console loses the hard enable signal, thus preventing it from performing work and ensuring operational safety. When the worktable is not in position, the proximity sensor is disconnected, the coil of relay KA1 is de-energized, and the second normally open contact is disconnected. In this state, regardless of whether the emergency stop input module is on, the safety relay cannot be turned on, and thus the machining control console loses the hard enable signal, thereby preventing it from performing work and ensuring operational safety.

[0073] The coil of relay KA2 has its first terminal connected to the first output terminal S14 of the safety relay, and its second terminal connected to the negative terminal of the power supply. The second output terminal S13 of the safety relay is connected to the positive terminal of the power supply. The first normally closed contact of relay KA2 is connected to the first reset branch terminal S33 of the safety relay via the ready input module, and its second terminal is connected to the second reset branch terminal S34 of the safety relay. The first normally open contact of relay KA2 is connected to the machining control console to transmit the hard enable signal, and its second terminal is connected to the negative terminal of the power supply. When the safety relay is disconnected, the normally closed contact of relay KA2 is closed, allowing the safety relay to be reset via the ready input module. When the safety relay is reset, it conducts, and relay KA2 is energized. On one hand, the normally open contact of relay KA2 closes, transmitting the hard enable signal to the machining control console; on the other hand, the normally closed contact of relay KA2 opens, preventing further reset until the safety relay is disconnected via a dual-circuit connection, at which point relay KA2 is de-energized and allowed to reset again.

[0074] It should be noted that terminals A1 and A2 of the safety relay are connected to the switching power supply to power the safety relay.

[0075] In this embodiment, the emergency stop input module and the ready input module are controlled manually or in a combination of manual and automatic operation at the rear of the equipment to activate the safety relay. This, in turn, activates relay KA2, transmitting a hard enable signal to the machining control console. The machining control console responds to the hard enable signal by performing table exchange or cutting operations. The workflow of the machining control console responding to the hard enable signal is detailed in subsequent embodiments and will not be repeated here.

[0076] This embodiment includes a safety relay, an emergency stop input module and a ready input module connected to the safety relay, and related relays. The emergency stop input module controls the conduction of the dual safety circuit of the safety relay, and the ready input module controls the conduction of the reset circuit of the safety relay. Based on the working principle of the safety relay conducting dual safety circuits and then resetting, the safety relay is activated, sending a hard enable signal to the processing control console. The processing control console responds to the hard enable signal to perform workbench exchange or cyclic processing. During processing, the operator performs loading and unloading operations and safety relay control operations from behind the equipment, eliminating the need to go to the front of the equipment. This allows for safe operation and cyclic processing, reducing the operator's operational complexity and improving work efficiency while ensuring safe loading and unloading.

[0077] like Figure 2 As shown, in some optional embodiments, the emergency stop input module is an emergency stop button SB1, and the ready input module is a ready button SB2. Both emergency stop buttons SB1 and ready buttons SB2 are located at the rear of the equipment. In this mode, the emergency stop buttons SB1 and SB2 are manually operated to turn the safety relay on or off. During processing, the operator controls the emergency stop buttons SB1 and SB2 at the rear of the equipment according to the real-time processing stage, thus achieving cyclical execution of the cutting process. This reduces the operator's operational complexity and improves work efficiency while ensuring safe loading and unloading. The process of achieving cyclical processing by manually operating the emergency stop buttons SB1 and SB2 to turn the safety relay on or off is detailed in subsequent embodiments and will not be repeated here.

[0078] In some alternative implementations, the emergency stop input module and the ready input module are controlled by a human operator at the rear of the equipment to activate or deactivate the safety relay. During the processing, the operator controls the ST switch at the rear of the equipment in conjunction with the real-time processing stage to achieve the cyclic execution of the cutting process. This reduces the complexity of operation for the operator and improves work efficiency while ensuring the safety of loading and unloading.

[0079] like Figure 3As shown, the emergency stop input module includes resistors R1, R2, and R3, capacitor C1, N-channel MOSFET Q1, diode D1, relay KA4, and switch ST; switch ST is located at the rear of the device. It should be noted that, due to space limitations, Figure 3 The output terminal of the safety relay is not shown; the unshown part is related to... Figure 2 The corresponding parts are the same.

[0080] The first end of resistor R1 is connected to the first output terminal of the machining control console, and the second end is connected to the gate of MOSFET Q1 in one path and to the negative terminal of the power supply through resistor R2 in another path. Capacitor C1 is connected in parallel with resistor R2. The drain of MOSFET Q1 is connected to the anode of diode D1, and the cathode of diode D1 is connected to the power supply. The source of MOSFET Q1 is connected to the negative terminal of the power supply. The coil of relay KA4 is connected in parallel with diode D1. One end of the first normally closed contact of relay KA4 is connected to the first input terminal S11 of the safety relay, and the other end is connected to the first terminal of the first normally open contact of relay KA1. One end of the second normally closed contact of relay KA4 is connected to the second input terminal S21 of the safety relay, and the other end is connected to the second terminal of the second normally open contact of relay KA1. The first end of switch ST is connected to the input terminal of the machining control console in one path and to the pull-up power supply through resistor R3 in another path. The second end of switch ST is connected to the negative terminal of the power supply.

[0081] The first output terminal of the machining control console outputs a high or low level to control the on / off state of relay KA4. When the output is low, relay KA4 is de-energized, and its two normally closed contacts remain closed, allowing the safety relay to conduct. When the first output terminal of the machining control console outputs a high level, relay KA4 is energized, and its two normally closed contacts open, preventing the safety relay from conducting. When the operator completes loading and unloading, they press switch ST. The machining control console receives the switch ST signal, determines that loading and unloading are complete, and then outputs a low level at its first output terminal, allowing the safety relay to conduct, thereby ensuring subsequent operations.

[0082] like Figure 3 As shown, the ready input module includes resistor R4, resistor R5, capacitor C2, N-channel MOSFET Q2, diode D2, relay KA5, and timer.

[0083] The first end of resistor R4 is connected to the second output terminal of the machining control console. The second end is connected to the gate of MOSFET Q2 in one path and to the negative terminal of the power supply via resistor R5 in another path. Capacitor C2 is connected in parallel with resistor R5. The drain of MOSFET Q2 is connected to the anode of diode D2, and the cathode of diode D1 is connected to the power supply. The source of MOSFET Q2 is connected to the negative terminal of the power supply. The coil of relay KA5 is connected in parallel with diode D2. The first end of the normally open contact of relay KA5 is connected to the reset branch terminal S33 of the safety relay, and the second end is connected to the normally closed contact of relay KA2. The timer is connected to the machining control console.

[0084] The second output terminal of the machining control console controls the on / off state of relay KA5 by outputting a high or low level. When the second output terminal outputs a high level, relay KA5 is energized, its normally open contact closes, and the safety relay resets. In the dual-circuit conduction mode, the safety relay conducts. When the second output terminal outputs a low level, relay KA5 is de-energized, its normally open contact opens, and a reset is allowed for the next operation. To achieve the reset upon next operation, a timer is connected to the machining control console. After relay KA5 has been energized for a certain period, relay KA5 is actively disconnected.

[0085] In these optional implementations, the operator controls switch ST, which, in conjunction with the emergency stop input module and the ready input module circuit, enables automatic control of the safety relays to be turned on or off by manual intervention from behind the equipment. To further enhance operational safety, these optional implementations also include a camera connected to the processing control console via a gateway. The processing control console analyzes the images of the workbench captured by the camera to determine whether loading and unloading are complete. After the operator presses switch ST, the captured image is used to determine whether loading and unloading are complete. Only if completion is detected is the activation of relay KA5 in the ready input module permitted. The process of manually operating switch ST in conjunction with the emergency stop input module and the ready input module to turn the safety relays on or off for cyclic processing is detailed in subsequent embodiments and will not be repeated here.

[0086] In some optional implementations, the system also includes a relay KA3 and an indicator LED. The first terminal of the coil of relay KA3 is connected to the second output terminal S24 of the safety relay, and the second terminal is connected to the negative terminal of the power supply. The second output terminal S23 of the safety relay is connected to the positive terminal of the power supply. The first terminal of the normally open contact of relay KA3 is connected to the positive terminal of the power supply, and the second terminal is connected to the negative terminal of the power supply via the indicator LED. The normally closed contact of relay KA3 is connected in series with the normally closed contact of relay KA2. The indicator LED is used to indicate whether the safety relay is conducting. The indicator LED can visually display the conducting state of the safety relay to the operator. When the safety relay is conducting, relay KA3 is energized, its normally open contact closes, and the indicator LED lights up, indicating that the system is in a normal working state. When the safety relay is de-energized, relay KA3 is de-energized, its normally open contact opens, the indicator LED goes out, and the operator can immediately know that the system has stopped working.

[0087] The foregoing has described in detail an embodiment of a laser cutting machine cyclic processing control system. Based on the laser cutting machine cyclic processing control system described in the above embodiment, this invention also provides a laser cutting machine cyclic processing control method corresponding to the system.

[0088] Figure 4 This is a schematic flowchart of a laser cutting machine cyclic processing control method provided by an embodiment of the present invention. The order of steps in this flowchart can be changed, and some steps can be omitted, depending on different requirements.

[0089] S1: Import the image files that need to be processed in batches into the processing console.

[0090] S2, set the number of processing cycles on the display screen of the machining console, click Start Processing, and configure the state machine of the machining console to the ready-to-process state.

[0091] S3 detects whether the workbench is in position using a proximity sensor. If it is in position, the safety relay is activated via the emergency stop input module and the ready input module, either manually or in a manual-automatic manner, from behind the equipment.

[0092] S4, the processing controller receives the hard enable signal, executes the cutting process, and configures the state machine to the processing in progress state.

[0093] S5, after the current processing is completed, the safety relay is disconnected by the emergency stop input module, either automatically or manually from the rear of the equipment.

[0094] S6, the processing controller configures the state machine to the processing completed state and checks whether the processing number has been reached. If so, proceed to step S7; otherwise, proceed to step S8.

[0095] S7, configure the state machine state to be "processing completed".

[0096] S8, controlled automatically or manually from behind the equipment, controls the safety relay to disconnect via the emergency stop input module, and the state machine of the processing console is configured to be in the state of preparing to exchange worktables.

[0097] S9, after loading and unloading are completed, the safety relay is activated by manual operation or manual-automatic operation at the rear of the equipment through the emergency stop input module and the ready input module.

[0098] S10, the machining controller receives the hard enable signal, executes the worktable exchange, and configures the state machine to the worktable exchange state.

[0099] S11: The proximity sensor detects whether the worktable is in position. If it is in position, the cutting process is executed, and the processing status of the state machine is configured. This process is repeated until the processing is completed.

[0100] First, import the batch of image files into the processing console and set the number of processing cycles to put the console into a processing-ready state. Next, the position of the worktable is detected by a proximity sensor. If it is in position, the safety relay is activated manually or through a combination of manual and automatic control at the rear of the machine. Upon receiving the hard enable signal, the processing controller begins cutting. After each processing cycle, the processing count is used to determine whether to end the process. If not, the safety relay is deactivated, and the system enters a worktable exchange preparation state. Once loading and unloading are complete, the safety relay is activated again to perform the worktable exchange. After the exchange is complete and the worktable is in position, cutting continues. This cycle repeats until all processing tasks are completed.

[0101] Operators can complete most operations from behind the equipment, such as controlling the on / off state of safety relays, without having to frequently travel back and forth between the front and back of the equipment, reducing operational complexity and improving work efficiency. The cyclic processing control method in this embodiment executes automatically according to a set process, with each step closely linked, enabling automated and orderly processing. Furthermore, through the configuration of a state machine, each stage of processing is precisely controlled, reducing human interference and improving processing accuracy and quality.

[0102] In some optional implementations, the safety relay is turned on by manual operation via the emergency stop input module and the ready input module at the rear of the device, and the safety relay is turned off by manual operation via the emergency stop input module at the rear of the device. These optional implementations are achieved by the emergency stop button SB1 and the ready button SB2.

[0103] The safety relay is activated manually via the emergency stop input module and the ready input module at the rear of the equipment. Specifically, this involves releasing the emergency stop button SB1 and then pressing the ready button SB2 to activate the safety relay.

[0104] The safety relay can be manually disconnected via the emergency stop input module at the rear of the equipment. Specifically, this involves pressing the emergency stop button SB1 to disconnect the safety relay.

[0105] In these alternative implementations, the laser cutting machine cycle processing control method specifically includes the following steps.

[0106] S101: Import the image files that need to be processed in batches into the processing console.

[0107] S102, set the number of processing cycles on the display screen of the machining console, click Start Processing, and configure the state machine of the machining console to the ready-to-process state.

[0108] S103: The proximity sensor detects whether the worktable is in position. If it is in position, the emergency stop button SB1 is released, and then the ready button SB2 is pressed to activate the safety relay.

[0109] S104, the machining controller receives the hard enable signal, executes the cutting process, and configures the state machine to the processing state.

[0110] S105, after the current processing is completed, press the emergency stop button SB1 to disconnect the safety relay.

[0111] S106, the processing controller configures the state machine to the processing completed state and checks whether the processing number has been reached. If so, proceed to step S107; otherwise, proceed to step S108.

[0112] S107, configure the state machine to state "processing completed".

[0113] S108, press the emergency stop button SB1 to disconnect the safety relay, and set the state machine of the machining control console to the ready-to-exchange-workbench state.

[0114] S109. After loading and unloading are completed, release the emergency stop button SB1, and then press the ready button SB2 to activate the safety relay.

[0115] S1010, the machining controller receives the hard enable signal, executes the worktable exchange, and configures the state machine to the worktable exchange state.

[0116] S1011 detects whether the worktable is in position using a proximity sensor. If it is in position, it performs cutting processing, configures the processing status of the state machine, and repeats this cycle until processing is completed.

[0117] In some alternative implementations, the safety relay is controlled to turn on by a human operator in conjunction with an automatic system via an emergency stop input module and a ready input module at the rear of the device, and to turn off automatically via the emergency stop input module.

[0118] In these alternative implementations, the laser cutting machine cycle processing control method specifically includes the following steps.

[0119] S201: Import the image files that need to be processed in batches into the processing console.

[0120] S202, set the number of processing cycles on the display screen of the machining console, click Start Processing, and configure the state machine of the machining console to the ready-to-process state.

[0121] S203 uses a proximity sensor to detect whether the workbench is in position. If it is, the safety relay is activated automatically via the emergency stop input module and the ready input module, with manual assistance from the operator at the rear of the equipment. Specifically, if the workbench is in position, the following steps are executed.

[0122] S203.1, Press switch ST.

[0123] S203.2, The machining control console detects whether it has received a signal from switch ST.

[0124] S203.3 When the ST stop signal is received, a low level is output at the first output terminal to turn off the emergency stop input module, and the first normally closed contact and the second normally closed contact of the relay KA4 remain closed.

[0125] S203.4 Receive the image of the workbench area and analyze the image of the workbench area to determine whether the loading and unloading are completed.

[0126] S203.5 If the loading and unloading are completed by analyzing the image of the workbench area, a high level is output at the second output terminal to turn on the ready input module, and the normally open contact of relay KA5 closes to turn on the safety relay.

[0127] S203.6 When the second output terminal outputs a high level, a timer is used to count the time. After a preset time, the second output terminal outputs a low level, which turns off the ready input module and opens the normally open contact of relay KA5.

[0128] S204, the machining controller receives the hard enable signal, executes the cutting process, and configures the state machine to the machining in progress state.

[0129] S205, after the current processing is completed, the safety relay is automatically disconnected via the emergency stop input module.

[0130] Specifically, after the current processing is completed, a high level is output at the first output terminal to turn on the emergency stop input module, and the first normally closed contact and the second normally closed contact of relay KA4 are opened to disconnect the safety relay.

[0131] S206, the processing controller configures the state machine to the processing completed state and checks whether the processing number has been reached. If so, proceed to step S207; otherwise, proceed to step S208.

[0132] S207, configure the state machine to state "processing completed".

[0133] S208, the safety relay is disconnected by the automatic emergency stop input module, and the state machine of the machining control console is set to the state of preparing to exchange worktables.

[0134] Specifically, a high level is output at the first output terminal to turn on the emergency stop input module, and the first normally closed contact and the second normally closed contact of relay KA4 are opened to disconnect the safety relay.

[0135] S209 After loading and unloading are completed, the safety relay is activated by manual intervention at the rear of the equipment via the emergency stop input module and the ready input module.

[0136] The activation of the safety relay in this step is the same as in steps S203.1 to S203.6 above, and will not be repeated here.

[0137] S2010, the machining controller receives the hard enable signal, executes the worktable exchange, and configures the state machine to the worktable exchange state.

[0138] S2011 uses a proximity sensor to detect whether the worktable is in position. If it is in position, the cutting process is executed, and the processing status is configured in the state machine. This cycle continues until the processing is completed.

[0139] In the above process, to ensure operational safety, after the operator manually sends a signal indicating that loading / unloading is complete via switch ST, image analysis is used to detect whether the loading / unloading is finished. The analysis of the workbench area image to determine whether loading / unloading is complete includes the following steps.

[0140] Step 1: Perform grayscale processing on the workbench area image.

[0141] Step 2: Based on the predefined positions of the first and second worktables, segment the worktable area image into a first region and a second region.

[0142] It should be noted that the top left corner of the workbench area image can be set as the origin (0, 0), and the bottom right corner as (W, H), where W is the width of the workbench area image and H is the height of the workbench area image.

[0143] First District Second Region This can be represented by a coordinate range, as follows:

[0144]

[0145] Step 3: Apply illumination compensation to the first and second regions using a Gaussian filter kernel.

[0146] Illumination compensation is expressed as

[0147] in, , Indicates the first before illumination compensation Coordinates in each region pixel values, Indicates the number after illumination compensation. Coordinates in each region pixel values, This represents the Gaussian filter kernel. Since the lighting conditions in the two regions may differ, illumination compensation is applied to each region separately to improve image processing accuracy.

[0148] Step 4: Apply Gaussian filtering to the first and second regions respectively using the following formulas for noise reduction.

[0149]

[0150]

[0151]

[0152] in, , Indicates the Gaussian filtering result of the first... Coordinates in each region pixel values, The size of the Gaussian kernel is determined. Indicates the first Gaussian function of each region Indicates the first The standard deviation of the Gaussian distribution in each region Indicates the first The standard deviation of gray levels in each region.

[0153] Step 5: Calculate the material coverage rate of the first and second regions using the following formulas respectively.

[0154]

[0155]

[0156] in, Indicates the first Inter-frame difference binary map of each region.

[0157] In these alternative implementations, material coverage is calculated using inter-frame difference binary images. To improve calculation accuracy, appropriate two frames should be selected.

[0158] In one optional implementation, the first frame image is selected from the image frame at the moment when the first output terminal outputs a high level, causing the safety relay to disconnect, and the second frame image is selected from the image frame when the ST-off signal is received.

[0159] Step 6: Extract the number of valid contours in the first and second regions respectively.

[0160] In one optional implementation, edge detection is performed on the first and second regions using Sobel gradient calculation. Based on the edge detection results, contour finding is performed using connected component analysis. The effective contours within the first and second regions are then extracted using the following formulas.

[0161]

[0162] in, Indicates the first A set of valid contours for each region. Indicates the first A silhouette area, This indicates the preset effective contour area threshold.

[0163] Step 7: Determine whether there is no material in the first region by the material coverage rate and the number of effective outlines in the first region, and determine whether there is material in the second region by the material coverage rate and the number of effective outlines in the second region.

[0164] Specifically, the following formula is used to determine whether there is no material in the first region.

[0165]

[0166] in, This indicates the preset first material coverage rate.

[0167] The presence of material in the second region can be determined using the following formula.

[0168]

[0169] in, This indicates the preset second material coverage rate. Representation and preset template The similarity of Hu moments between them.

[0170] Step 8: If there is no material in the first area and there is material in the second area, then the loading and unloading is considered complete.

[0171] Coverage assessment eliminates misjudgments caused by noise, lighting fluctuations, or small debris, ensuring that materials occupy a sufficiently large effective area. Shape matching using the effective contour count ensures that the shape of the covered area matches the expected shape of the target material, avoiding misjudgments of other objects (such as tools, debris, or shadows). By combining coverage and shape matching conditions, the system can reliably distinguish between real materials and interference objects in complex industrial environments, ensuring the accuracy of loading and unloading status determination.

[0172] For example:

[0173] The coverage rate reached 80%, and a contour with a height similar to the template was detected, indicating the presence of material;

[0174] The coverage rate reached 70%, but the matching degree of all contour shapes was low, indicating that there was no material (possibly other objects or noise).

[0175] There are small fragments that match the shape of the template, but the coverage is only 20%, so it is determined that there is no material (the fragments do not reach the effective coverage).

[0176] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A laser cutting machine cycle processing control system, characterized by, The safety relay, the relay KA1, the relay KA2, the emergency stop input module, the ready input module, and the proximity sensor for detecting the position of the workbench are included. The first end of the coil of the relay KA1 is connected to the positive pole of the power supply, and the second end is connected to the negative pole of the power supply through the proximity sensor. The first end of the first normally open contact of the relay KA1 is connected to the first input terminal one of the safety relay through the emergency stop input module, and the second end is connected to the first input terminal two of the safety relay. The first end of the second normally open contact of the relay KA1 is connected to the first input terminal one of the safety relay through the emergency stop input module, and the second end is connected to the first input terminal two of the safety relay. The proximity sensor is connected to the processing console. The first end of the coil of the relay KA2 is connected to the first output terminal one of the safety relay, and the second end is connected to the negative pole of the power supply. The second output terminal two of the safety relay is connected to the positive pole of the power supply. The first end of the normally closed contact of the relay KA2 is connected to the reset branch terminal one of the safety relay through the ready input module, and the second end is connected to the reset branch terminal two of the safety relay. The first end of the normally open contact of the relay KA2 is connected to the processing console to transmit the hard enable signal to the processing console, and the second end is connected to the negative pole of the power supply. The emergency stop input module and the ready input module are controlled by manual operation or manual cooperation with automatic mode to turn on the safety relay, and then the relay KA2 operates to transmit the hard enable signal to the processing console. The processing console responds to the hard enable signal to perform workbench exchange or cutting processing. The emergency stop input module is an emergency stop button SB1, and the ready input module is a ready button SB2. The emergency stop button SB1 and the ready button SB2 are arranged at the rear of the equipment. Alternatively, the emergency stop input module includes a resistor R1, a resistor R2, a resistor R3, a capacitor C1, an N-channel MOS tube Q1, a diode D1, a relay KA4, and a switch ST. The switch ST is arranged at the rear of the equipment. The first end of the resistor R1 is connected to the first output end of the processing console, and the second end is connected to the gate of the MOS tube Q1 through one path and to the negative pole of the power supply through another path. The capacitor C1 is connected in parallel with the resistor R2. The drain of the MOS tube Q1 is connected to the positive pole of the diode D1, and the negative pole of the diode D1 is connected to the power supply. The source of the MOS tube Q1 is connected to the negative pole of the power supply. The coil of the relay KA4 is connected in parallel with the diode D1. One end of the first normally closed contact of the relay KA4 is connected to the first input terminal one of the safety relay, and the other end is connected to the first end of the first normally open contact of the relay KA1. One end of the second normally closed contact of the relay KA4 is connected to the first input terminal one of the safety relay, and the other end is connected to the second end of the second normally open contact of the relay KA1. The first end of the switch ST is connected to the input end of the processing console through one path and to the pull-up power supply through another path. The second end of the switch ST is connected to the negative pole of the power supply.

2. The laser cutting machine cycle process control system of claim 1, wherein, The ready input module includes a resistor R4, a resistor R5, a capacitor C2, an N-channel MOS tube Q2, a diode D2, a relay KA5, and a timer. The first end of the resistor R4 is connected to the second output end of the processing console, the second end is connected to the gate of the MOS tube Q2 in one way, and is connected to the negative electrode of the power supply through the resistor R5 in the other way, and the capacitor C2 is connected to the resistor R5 in parallel; the drain of the MOS tube Q2 is connected to the positive electrode of the diode D2, the negative electrode of the diode D1 is connected to the power supply; and the source of the MOS tube Q2 is connected to the negative electrode of the power supply; The coil of the relay KA5 is connected to the diode D2 in parallel, the normally open contact of the relay KA5 is connected to the reset branch terminal one of the safety relay in the first end, and is connected to the normally closed contact of the relay KA2 in the second end; The timer is connected to the processing console.

3. The laser cutting machine cycle process control system according to claim 1 or 2, characterized in that, The system further comprises a camera, the camera is connected to the processing console through the gateway, and the processing console analyzes the workbench image shot by the camera to determine whether the feeding and discharging are completed.

4. The laser cutting machine cycle process control system according to claim 1 or 2, characterized in that, The system further comprises a relay KA3 and an indicator lamp LED; The first end of the coil of the relay KA3 is connected to the second output terminal one of the safety relay, the second end is connected to the negative electrode of the power supply, the second output terminal two of the safety relay is connected to the positive electrode of the power supply; the first end of the normally open contact of the relay KA3 is connected to the positive electrode of the power supply, the second end is connected to the negative electrode of the power supply through the indicator lamp LED; and the normally closed contact of the relay KA3 is connected to the normally closed contact of the relay KA2 in series.

5. A method for controlling the cyclic processing of a laser cutting machine, characterized in that, The system based on any one of claims 1-4 comprises the following steps: Importing the image file needing batch processing into the processing console; Setting the number of cycles of processing on the display screen of the processing console, clicking start processing, and configuring the state of the state machine of the processing console as a preparation processing state; Detecting whether the workbench is in place through the proximity sensor, if yes, controlling the safety relay to be turned on by manually operating or manually cooperating with automatic mode through the emergency stop input module and the ready input module at the rear of the equipment; The processing controller receives a hard enable signal, executes cutting processing, and configures the state of the state machine as a processing state; After the current processing is completed, the safety relay is controlled to be turned off by automatic mode or manually operating at the rear of the equipment through the emergency stop input module; The processing controller configures the state of the state machine as a processing completion state, and detects whether the number of processing has been reached; If yes, configuring the state of the state machine as a processing end; If not, the safety relay is controlled to be turned off by automatic mode or manually operating at the rear of the equipment through the emergency stop input module, and the processing console configures the state of the state machine as a preparation workbench exchange state; After the feeding and discharging are completed, the safety relay is controlled to be turned on by manually operating or manually cooperating with automatic mode through the emergency stop input module and the ready input module at the rear of the equipment; The processing controller receives a hard enable signal, executes workbench exchange, and configures the state of the state machine as a workbench exchange state; Detecting whether the workbench is in place through the proximity sensor, if yes, executing cutting processing, and configuring the processing state of the state machine, and repeating the above steps until the processing is completed.

6. The laser cutting machine cycle process control method of claim 5, wherein, Controlling the safety relay to be turned on by manually operating at the rear of the equipment through the emergency stop input module and the ready input module, specifically comprising: Releasing the emergency stop button SB1, and then pressing the ready button SB2 to make the safety relay turned on; The safety relay is turned off by the manual operation mode through the emergency stop input module at the rear of the device, specifically including: The safety relay is turned off by pressing the emergency stop button SB1.

7. The method of claim 5, wherein, The safety relay is turned on by the manual operation mode through the emergency stop input module and the ready input module at the rear of the device, specifically including: Pressing the switch ST; The processing console detects whether the switch ST pressing signal is received; When the switch ST pressing signal is received, a low level is output at the first output end, the emergency stop input module is turned off, and the first normally closed contact and the second normally closed contact of the relay KA4 remain closed; The workbench area image is received, and the workbench area image is analyzed to determine whether the feeding and discharging are completed; If the feeding and discharging are completed through the workbench area image analysis, a high level is output at the second output end, the ready input module is turned on, and the normally open contact of the relay KA5 is closed to turn on the safety relay; The timer is timed when the high level is output at the second output end, and after the preset time period, a low level is output at the second output end, the ready input module is turned off, and the normally open contact of the relay KA5 is opened; The safety relay is turned off by the automatic mode through the emergency stop input module, specifically including: A high level is output at the first output end, the emergency stop input module is turned on, the first normally closed contact and the second normally closed contact of the relay KA4 are opened, and the safety relay is turned off.

8. The laser cutting machine cycle process control method of claim 7, wherein, The workbench area image is analyzed to determine whether the feeding and discharging are completed, specifically including: The workbench area image is subjected to grayscale processing; The workbench area image is divided into a first area and a second area according to the positions of the first workbench and the second workbench defined in advance; The first area and the second area are subjected to illumination compensation through a Gaussian filter kernel respectively; The first area and the second area are subjected to Gaussian filtering for noise reduction through the following formula respectively, wherein, , represents the pixel value of the coordinate in the th region after Gaussian filtering, determines the size of the Gaussian kernel, represents the Gaussian function of the th region, represents the standard deviation of the Gaussian distribution of the th region, represents the gray scale standard deviation of the th region; The material coverage rates of the first area and the second area are calculated through the following formula respectively, wherein, represents the interframe difference binary map of the region; The number of effective contours in the first area and the second area is extracted respectively; Whether there is no material in the first area and whether there is material in the second area are determined through the material coverage rate and the number of effective contours of the first area and the second area respectively; If there is no material in the first area and there is material in the second area, it is determined that the feeding and discharging are completed.

Images